Method for deforming a web

ABSTRACT

The present invention is directed to methods for deforming a web comprising the steps of supplying a first layer of a web; weakening the first layer at a plurality of locations to create a plurality of weakened, melt-stabilized locations in the first layer; supplying a second layer of the web onto at least part of the first layer; and forming a plurality of first features in the first layer and a plurality of second features throughout the first and second layers of the web in the z-direction, wherein the plurality of first and second features are formed simultaneously.

FIELD OF THE INVENTION

The present invention relates to methods and apparatuses for deforming aweb.

BACKGROUND OF THE INVENTION

Laminate webs containing a film layer and/or a fibrous nonwoven layerare well known in the art. Three-dimensionally deformed laminate websare utilized in a wide variety of industrial and consumer products. Forexample, nonwoven webs are often laminated with polymer films such thatthey are useful as materials in disposable products such as topsheets ondisposable absorbent articles.

Apertured webs are known for use in disposable absorbent articles suchas feminine hygiene articles including sanitary napkins, and disposablediapers and the like. Such articles typically have a fluid pervioustopsheet, a fluid impervious breathable backsheet, and an absorbent coredisposed between the topsheet and the backsheet. Apertured webs can bemade to form a fluid pervious topsheet and/or the fluid imperviousbreathable backsheet in absorbent articles. Webs having loops or tuftsare also desirable as such webs have a bulky texture and/or softness.

Designers of absorbent articles are faced with the challenge ofdesigning articles that provide for healthy skin in all regions of thewearer's crotch. In some instances, the benefit of providing for skinhealth in one region is obtained at the expense of decreased skin healthin another region. Designs that apply a uniform approach across theentire absorbent article may not provide for satisfactory skin healthand fluid acquisition throughout the entire crotch region. Furthermore,skin health and the feeling of wetness can impact how comfortable theabsorbent article is to wear.

Meanwhile, various fluid handling demands on different portions of anabsorbent article, and different physical interactions between portionsof an absorbent article and portions of a wearer's body create uniqueneeds for different regions of the topsheet which may be met by formingdifferent structures in different regions. In addition, expectation ofenhanced perceptions of functionalities of absorbent articles such asabsorbency and breathability also creates needs for structural featuresin predetermined regions of the topsheet. To meet such needs, one layerof the web, or multiple layers of the web may be deformed to formdifferent structures in predetermined regions.

In many cases to provide best functionality and enhanced perceptions ofabsorbent articles, several structures may be formed in a continuousprocess comprising multiple unit steps. Formation of features in a webin a different sequence may cause weakening of the web structure,thereby causing tearing during the manufacturing process or in use.Further, separation of unit steps of structure formations may increasethe possibility that some or many structures closely co-located in a webformed in different unit steps overlap.

A need exists for processes and apparatuses that will allow a web to bedeformed to have structures in different regions via single unitoperation. Especially, a need exists for processes and apparatuses thatare capable of deforming a web where at least one of structures isformed in one layer or limited numbers of layers of the web while otherstructures are formed through the entire web in z-dimension.

SUMMARY OF THE INVENTION

The present invention is directed to methods for deforming a multilayerweb comprising the steps of supplying a first layer of a web; weakeningthe first layer at a plurality of locations to create a plurality ofweakened, melt-stabilized locations in the first layer; supplying asecond layer of the web onto at least part of the first layer; forming aplurality of first features in the first layer and a plurality of secondfeatures throughout the first and second layers of the web in thez-direction, wherein the plurality of first and second features areformed simultaneously.

The methods and apparatuses of the present invention can, in certainnon-limiting embodiments, be configured for deforming a multilayer webin a single nip. In one embodiment, the method involves feeding a webhaving a plurality of weakened, melt-stabilized locations in a firstlayer of the web into a nip that is formed between two intermeshingrolls. The two rolls are configured for deforming a web with at leasttwo sets of deformations wherein one of the two set of deformations isformed in the first layer of the web while the other set of deformationis formed throughout the web in z-dimension. In such an embodiment, aplurality of first features and a plurality of second features areformed by feeding the web in a machine direction into a nip that isformed between two intermeshing rolls comprising a first roll comprisinga first region comprising a plurality of first forming elements whereinthe plurality of first forming elements comprise a plurality ofcircumferentially-extending ridges separated by grooves, and a secondregion comprising a plurality of circumferentially-extending ridgesseparated by grooves on its surface; and a second roll comprising afirst region comprising a plurality of circumferentially-extendingridges separated by grooves and a second region comprising a pluralityof second forming elements on its surface.

In another embodiment, a process according to the present inventioninvolves further forming a third set of deformation in a third area ofthe web where the second layer does not exist. In such an embodiment,when for example two intermeshing rolls is used to deform the web asillustrated above, a first roll may further comprise a third regioncomprising a plurality of third forming elements on its surface, and asecond roll may further comprise a third region comprising a pluralityof circumferentially-extending ridges separated by grooves on itssurface. When the web is fed into the nip, at least some of theplurality of first forming elements in the first region of the firstroll and at least some of ridges in the first region of the second rollare intermeshed to from the plurality of first features. The secondforming elements of the second roll and the optional third formingelements of the first roll form the plurality of second features and theplurality of optional third features, respectively.

BRIEF DESCRIPTION OF THE DRAWINGS

The following detailed description will be more fully understood in viewof the drawings in which:

FIG. 1 is a schematic side view of one embodiment of a method andapparatus for deforming a web according to the present invention.

FIG. 2 is a perspective illustration of an exemplary structure of aweakening unit of the process of FIG. 1.

FIG. 3 is a perspective illustration of another exemplary structure of aweakening unit of the process of FIG. 1.

FIG. 4 is a perspective view of a pair of mated forming structures.

FIG. 5 is a perspective illustration of a process to provide atensioning force on a web using mated forming structures of FIG. 4.

FIG. 6 is a perspective view of another pair of mated formingstructures.

FIG. 7A is an enlarged perspective view of a CD SELF roll with astaggered pattern of teeth thereon.

FIG. 7B is a cross-section of a portion of the mated forming structuresshown in FIG. 6.

FIG. 7C is an enlarged perspective view of a MD SELF roll with astaggered pattern of teeth thereon.

FIG. 8 is a perspective view of another pair of mated formingstructures.

FIG. 9 is a fragmented cross-sectional view through a portion of the nipbetween a pair of rolls having forming elements to form embossingsuitable for the methods and apparatuses.

FIG. 10 is a perspective view of a forming structure in accordance withthe present invention.

FIG. 11 is a perspective view of another forming structure in accordancewith the present invention.

FIG. 12 is a top perspective view of a web that can be producedaccording to the present process using the forming structure in FIG. 11.

FIG. 13 is a view of intermeshing engagement of portions of the formingstructure of FIG. 11.

FIG. 14A is a view of a portion of a first roll of the forming structureshown in FIG. 13.

FIG. 14B is a view of a portion of a second roll of the formingstructure shown in FIG. 13.

FIG. 15 is a schematic representation of exemplary third formingelements of FIG. 14B.

FIG. 16 is a schematic side view of another embodiment of a formingstructure in accordance with the present invention.

The embodiments shown in the drawings are illustrative in nature and arenot intended to be limiting of the invention defined by the claims.Moreover, the features of the invention will be more fully apparent andunderstood in view of the detailed description.

DETAILED DESCRIPTION

The term “absorbent article” includes disposable articles such assanitary napkins, panty liners, tampons, interlabial devices, wounddressings, diapers, adult incontinence articles, wipes, and the like.Still further, the absorbent members produced by the methods andapparatuses disclosed herein can find utility in other webs such asscouring pads, dry-mop pads (such as SWIFFER® pads), and the like. Atleast some of such absorbent articles are intended for the absorption ofbody liquids, such as menses or blood, vaginal discharges, urine, andfeces. Wipes may be used to absorb body liquids, or may be used forother purposes, such as for cleaning surfaces. Various absorbentarticles described above will typically comprise a liquid pervioustopsheet, a liquid impervious backsheet joined to the topsheet, and anabsorbent core between the topsheet and backsheet.

The term “absorbent core”, as used herein, refers to the component ofthe absorbent article that is primarily responsible for storing liquids.As such, the absorbent core typically does not include the topsheet orbacksheet of the absorbent article.

The term “absorbent member”, as used herein, refers to the components ofthe absorbent article that typically provide one or more liquid handlingfunctionality, e.g., liquid acquisition, liquid distribution, liquidtransportation, liquid storage, etc. If the absorbent member comprisesan absorbent core component, the absorbent member can comprise theentire absorbent core or only a portion of the absorbent core.

The term “absorbent structure”, as used herein, refers to an arrangementof more than one absorbent component of an absorbent article.

The term “adjacent”, as used herein, with reference to features, areas,or regions, means near or close to, and which need not be in contactwith each other.

The term “aperture”, as used herein, refers to a hole. The apertures caneither be punched cleanly through the web so that the materialsurrounding the aperture lies in the same plane as the web prior to theformation of the aperture (a “two dimensional” aperture), or holesformed in which at least some of the material surrounding the opening ispushed out of the plane of the web. In the latter case, the aperturesmay resemble a protrusion or depression with an aperture therein, andmay be referred to herein as a “three dimensional” aperture, a subset ofapertures.

The term “component” of an absorbent article, as used herein, refers toan individual constituent of an absorbent article, such as a topsheet,acquisition layer, liquid handling layer, absorbent core or layers ofabsorbent cores, backsheets, and barriers such as barrier layers andbarrier cuffs.

The term “cross-machine direction” or “CD” means the path that isperpendicular to the machine direction in the plane of the web.

The term “deformable material”, as used herein, is a material which iscapable of changing its shape or density in response to applied stressesor strains. Such deformable materials may be chemically homogeneous orheterogeneous, such as homopolymers and polymer blends, structurallyhomogeneous or heterogeneous, such as plain sheets or laminates, or anycombination of such materials.

The term “discrete”, as used herein, means distinct or unconnected. Whenthe term “discrete” is used relative to forming elements on a formingmember, it is meant that the distal (or radially outwardmost) ends ofthe forming elements are distinct or unconnected in all directions,including in the machine and cross-machine directions (even though basesof the forming elements may be formed into the same surface of a roll,for example).

The term “forming element(s)”, as used herein, refers to any elements onthe surface of a forming member that are capable of deforming a web. Theterm “forming element(s)” includes both continuous or non-discreteforming elements such as the ridges and grooves on ring rolls, anddiscrete forming elements such as teeth.

The term “intermixed”, as used herein, refers to features that aredistributed between other features over at least some portion of thesurface of a component, in which the features differ from each other asdescribed herein. The term “intermixed” comprises arrangements offeatures in which at least two of the closest features in any direction(including, but not limited to longitudinal, transverse, or diagonal)differ from each other as described herein, even though there may be asimilar feature that is as close as, or closer to, a given feature inanother direction.

The term “Interpenetrating SELF” and the acronym “IPS”, as used herein,refers to a process that uses The Procter & Gamble Company's SELFtechnology (described below) to combine at least two layers or materialstogether. Tufts may be formed in both materials; or, the tuft of onematerial may burst through the other material. Interpenetrating SELF isdescribed in greater detail in U.S. Pat. No. 7,648,752.

The term “joined to” encompasses configurations in which an element isdirectly secured to another element by affixing the element directly tothe other element; configurations in which the element is indirectlysecured to the other element by affixing the element to intermediatemember(s) which in turn are affixed to the other element; andconfigurations in which one element is integral with another element,i.e., one element is essentially part of the other element. The term“joined to” encompasses configurations in which an element is secured toanother element at selected locations, as well as configurations inwhich an element is completely secured to another element across theentire surface of one of the elements. The term “joined to” includes anyknown manner in which elements can be secured including, but not limitedto mechanical entanglement.

The term “layer” is used herein to refer to an absorbent member whoseprimary dimension is X-Y, i.e., along its length (or longitudinaldirection) and width (or transverse direction). It should be understoodthat the term “layer” is not necessarily limited to single layers orsheets of material. Thus the layer can comprise laminates orcombinations of several sheets or webs of the requisite type ofmaterials. Accordingly, the term “layer” includes the terms “layers” and“layered”.

The term “machine direction” or “MD” means the path that material, suchas a web, follows through a manufacturing process.

The term “male/female embossing” as used herein, refers to an embossingapparatus and process that involves the use of at least a pair ofpatterned rolls, wherein the first patterned roll comprises one or moreprojections or protrusions, and the second patterned roll comprises oneor more recesses into which one or more of the projections of the firstpatterned roll mesh. The projections and recesses may be discreteembossing elements, and they may have matched or unmatched patterns. Theterm “male/female embossing”, thus, excludes embossing processes thatutilize the combination of a patterned roll against a flat anvil roll ordeformable roll.

The term “macroscopic”, as used herein, refers to structural features orelements that are readily visible and distinctly discernable to a humanhaving 20/20 vision when the perpendicular distance between the viewer'seye and the web is about 12 inches (30 cm). Conversely, the term“microscopic” refers to such features that are not readily visible anddistinctly discernable under such conditions.

The terms “mechanically impacting” or “mechanically deforming”, may beused interchangeably herein, to refer to processes in which a mechanicalforce is exerted upon a material.

The term “Micro-SELF” is a process that is similar in apparatus andmethod to that of the SELF process defined herein. Micro-SELF teeth havedifferent dimensions such that they are more conducive to forming tuftswith openings on the leading and trailing edges. A process usingmicro-SELF to form tufts in a web substrate is disclosed in U.S. Patentapplication Publication No. US 2006/0286343A1.

The term “permanently deformed”, as used herein, refers to the state ofa deformable material whose shape or density has been permanentlyaltered in response to applied stresses or strains.

The term “rib-like structure(s)”, as used herein, refers to anembossment, debossment or a combination thereof which has a major axisand a minor axis. Preferably, the major axis is at least as long as theminor axis. The major axes of the rib-like structures are preferablyoriented substantially perpendicular to the axis of applied elongation.Rib-like structures may have continuous side walls associated therewith,i.e., a continuous “transition zone,” and may not exhibit rupturing of aweb. Rib-like structure(s) is understood to include tufts.

The terms “ring roll” or “ring rolling” refer to a process usingdeformation members comprising counter rotating rolls, intermeshingbelts or intermeshing plates containing continuous ridges and grooveswhere intermeshing ridges (or projections) and grooves (or recesses) ofdeformation members engage and stretch a web interposed therebetween.For ring rolling, the deformation members can be arranged to stretch theweb in the cross machine direction or the machine direction depending onthe orientation of the ridges and grooves.

The term “rotary knife aperturing” (RKA) refers to a process andapparatus using intermeshing forming elements similar to those describedherein with respect to SELF or micro-SELF forming elements. The RKAprocess differs from SELF or micro-SELF in that the SELF or micro-SELFforming elements which are relatively flat, elongated teeth have beenmodified to be pyramid shaped, elongated with at least six sides, thesides being substantially triangular and tapered to a point at thedistal end. The RKA teeth can be sharpened to cut through as well asdeform a web to produce an apertured web, or in some cases, athree-dimensionally apertured web, as disclosed in U.S. PatentApplication Publication Nos. US 2005/0064137A1, US 2006/0087053A1, andUS 2005/021753.

The terms “SELF” or “SELFing”, refer to Procter & Gamble technology inwhich SELF stands for Structural Elastic Like Film. While the processwas originally developed for deforming polymer film to have beneficialstructural characteristics, it has been found that the SELFing processcan be used to produce beneficial structures in other materials.Processes, apparatuses with SELF teeth, and patterns produced via SELFare illustrated and described in U.S. Pat. Nos. 5,518,801; 5,691,035;5,723,087; 5,891,544; 5,916,663; 6,027,483; and 7,527,615.

The term “tuft”, as used herein, refers to a particular type ofprotrusion. Tufts may have a tunnel-like configuration, and in somecases may be open at one or both of their ends.

The term “Z-dimension” refers to the dimension orthogonal to the lengthand width of a web. The Z-dimension usually corresponds to the thicknessof the web.

I. Deformed Web.

The present inventions are directed to methods and apparatuses fordeforming a web. Methods and apparatuses are disclosed that are capableof forming new structures in webs that provide the webs with additionalproperties. It should be understood that while the term “deformed web”is utilized herein, the object is to create components, such asabsorbent members (or non-absorbent components), for absorbent articlesfrom such deformed web. In such cases, the deformed web will be cut intoindividual components for absorbent articles. The deformed web can alsobe used in products other than absorbent articles including, but notlimited to packaging materials and trash bags.

Structures which can be provided in webs and the components formedtherefrom include features extending out of the plane of the web on atleast one side thereof. In the case of webs used in absorbent articles,such structures may include those that provide a single portion of theweb with at least one property (such as improved softness, fluidhandling, or other properties) in a predetermined portion of the web.

The process can allow a precursor web comprising a first layer and asecond layer to be deformed simultaneously wherein the web is deformedin at least one first area where the second layer is not deformed and inat least one second area where both the first and second layers aredeformed. The first area and the second area may be distinctivelyseparated each other, or overlap each other at least in part.

The process can also allow a precursor web comprising a first layer anda second layer to be deformed simultaneously in at least three areaswherein the web is deformed in at least one first area where the secondlayer is not deformed, in at least one second area where both the firstand second layers are deformed, and in at least one third area where thesecond layer does not exist. The first area and the second area may bedistinctively separated each other, or overlap at least in part.

The deformed web or precursor web comprises a first layer and a secondlayer each of which comprises any suitable deformable material. Such asuitable deformable material can be a woven, nonwoven, film, paper,tissue, knitted fabric, combination, composite, or laminate of any ofthe foregoing materials.

As used herein, the term a “nonwoven” refers to a material having astructure of individual fibers or threads which are interlaid, but notin a repeating pattern as in a woven or knitted fabric, which do nottypically have randomly oriented fibers. Nonwoven or fabrics have beenformed from many processes, such as, for example, meltblowing,spunbonding, hydroentangling, airlaid, wetlaid, through-air-dried papermaking processes, and bonded carded web processes, including cardedthermal bonding. The woven, nonwoven, film, combination, or laminate canbe made of any suitable materials including, but not limited to naturalmaterials, synthetic materials, and combinations thereof. Suitablenatural materials include, but are not limited to cellulose, cottonlinters, bagasse, wool fibers, silk fibers, etc. In some embodiments,the web materials may be substantially free of cellulose, and/or excludepaper materials. In other embodiments, the methods described herein maybe performed on cellulose-containing precursor materials.

As used herein, the term a “polymeric film” comprise thermoplasticpolymers having characteristic rheological properties which depend ontheir composition and temperature. Below their glass transitiontemperature, such thermoplastic polymers can be hard, stiff, and/orbrittle. Below the glass transition temperature, the molecules are inrigid, fixed positions. Above the glass transition temperature but belowthe melt temperature range, thermoplastic polymers exhibitviscoelasticity. In this temperature range, the thermoplastic materialgenerally has a certain degree of crystallinity, and is generallyflexible and to some degree deformable under a force. The deformabilityof such a thermoplastic is dependent on the rate of deformation, amount(dimensional quantity) of deformation, length of time it is deformed,and its temperature. In one embodiment, processes can be utilized toform materials comprising thermoplastic polymers, especiallythermoplastic film, which are within this viscoelastic temperaturerange. Polymeric film can comprise a certain amount of ductility.Ductility, as used herein, is the amount of permanent, unrecoverable,plastic strain which occurs when a material is deformed, prior tofailure (rupture, breakage, or separation) of the material. Materialsthat can be used as described herein can have a minimum ductility of atleast about 10%, or at least about 50%, or at least about 100%, or atleast about 200%. Polymeric film webs can include materials normallyextruded or cast as films such as polyolefins, nylons, polyesters, andthe like. Such films can be thermoplastic materials such aspolyethylene, low density polyethylene, linear low density polyethylene,polypropylenes and copolymers and blends containing substantialfractions of these materials. Such films can be treated with surfacemodifying agents to impart hydrophilic or hydrophobic properties, suchas imparting a lotus effect. As noted below, polymeric film can betextured or otherwise altered from a strictly flat, planarconfiguration.

In one non-limiting embodiment, the deformed web comprises a) aplurality of first features comprising apertures formed in a first layerin a first area of the web, and b) a plurality of second features formedin a second area of the web throughout the web in z-dimension. In casethe web is a two-layer web, the second features are formed in the firstlayer only. In case the web is a three or more layer web, the secondfeatures may be formed in the first layer only or through the entirelayers exiting in the second area.

In another non-limiting embodiment, the deformed web further comprises aplurality of third features formed in at least one third area of the webwhere the second layer of the web does not exist.

In some embodiments, the second features and/or the third features maybe selected from the group consisting of one or more of the foregoingtypes of features. For example, the second and/or third features cancomprise apertures, protrusions, or depressed areas (or “depressions”).The second features may be of a different type and/or have differentproperties or characteristics than the first features or the optionalthird features. The deformed web may further comprise fourth or moreformed features. The fourth, or more features may comprise any of thetypes of features or have any of the properties described herein, andmay differ from the first and second features in any such aspects.

The first features and second features may be of any suitable size.Typically, either the first features or the second features can bemacroscopic. In some embodiments, the first features and the secondfeatures will both be macroscopic. The plan view area of the individualfeatures may, in some embodiments of the web, be greater than or equalto about 0.5 mm², 1 mm², 5 mm², 10 mm², or 15 mm², or lie in any rangebetween two of these numbers. The methods described herein can, however,be used to create first features and/or second features that aremicroscopic which have plan view areas less than 0.5 mm².

The second features and the optional third features, and other optionalfeatures may be of any suitable configuration. The features may becontinuous and/or discrete. Suitable configurations for the featuresinclude, but are not limited to: ridges (continuous protrusions) andgrooves (continuous depressions); tufts; columnar shapes; dome-shapes,tent-shapes, volcano-shapes; features having plan view configurationsincluding circular, oval, hour-glass shaped, star shaped, polygonal,polygonal with rounded corners, and the like, and combinations thereof.Polygonal shapes include, but are not limited to rectangular (inclusiveof square), triangular, hexagonal, or trapezoidal.

The first features and the second features may differ from each other interms of one or more of the following properties: type, shape, size,aspect ratio, edge-to-edge spacing, height or depth, density, color,surface treatment (e.g., lotion, etc.), number of web layers within thefeatures, and orientation (protruding from different sides of the web).The term “type”, as used herein, refers to whether the feature is anaperture (a two dimensional aperture, or a three dimensional aperture),a protrusion (a tuft, or other kind of protrusion), or a depression. Twofeatures will be considered to be different in type if one featurecomprises one of these features listed (for example, a two dimensionalaperture), and the other feature comprises another one of the listedfeatures (for example, a three dimensional aperture). When the featuresare described as differing from each other in one of more of theproperties listed above, it is meant to include those differences otherthan minor differences that are the result of variations withinmanufacturing tolerances. It should also be understood that although theweb may have discrete thermal or adhesive bond sites therein, in someembodiments the features of interest imparted by this process herein donot include such bond sites.

In one embodiment, the second discrete features are features selectedfrom the group consisting of apertures, protrusions, depressions, tufts,and combinations thereof. In another embodiment, the first features areapertures and the second features are tufts.

The various types of deformed webs will be shown in conjunction with thedescriptions of the apparatuses and methods used to form the same. Thesewebs can be cut to form various components of products such as absorbentarticles (such as topsheets, backsheets, acquisition layers, absorbentcores), packaging (such as flow wrap, shrink wrap, and polybags), trashbags, food wrap, wipes, facial tissue, toilet tissue, paper towels, andthe like.

II. Processes and Apparatuses for Deforming Webs

It is desirable to design a process that enables better control over theformation of two or more sets of features. An approach for achievingbetter control over the formation of each set of features is providedhere. The approach utilizes a single nip with two rolls comprisingdiscrete male forming elements wherein at least one roll comprises twoor more ridges. This approach may enable better control over theformation of each set of features in a single unit operation. Thisapproach may enable the formation of multiple features in a single unitoperation, which eliminates or mitigate the risks of overlapping ofthese features if they were formed in separate steps, and ofmisalignment or overlapping of these features due to tracking variation.In addition, it also provides the benefit of much less space required onan absorbent article production line, which increasingly becomes premiumfor productivity perspectives.

FIG. 1 shows one non-limiting embodiment of a process of the presentinvention and an apparatus that can be used in the process. In FIG. 1,the machine direction is from left to right. Process 100 carried outaccording to the example in FIG. 1 comprises supplying a first layer 11to a weakening unit 150 to weaken the first layer at a plurality oflocations to create a plurality of weakened, melt-stabilized locationsin the first layer. Then, a second layer 12 is supplied onto the firstlayer 11 in order to overlap at least part of the first layer 11 to forma precursor web 10. The precursor web 10 is supplied to a forming unit160 to form a plurality of first features and a plurality of secondfeatures on the precursor web 10 simultaneously to provide a deformedweb 20.

FIGS. 2 and 3 are exemplary structures of the weakening unit 150 of theprocess 100 of FIG. 1.

Referring to FIGS. 1 and 2, a precursor web 10 travels and passesthrough a nip 106 of a web weakening roll arrangement 108 formed byrolls 110 and 112. The web weakening roll arrangement 108 preferablycomprises a patterned calendar roll 110 and a smooth anvil roll 112. Oneor both of the patterned calendar roll 110 and the smooth anvil roll 112may be heated and the pressure between the two rolls may be adjusted bywell known means to provide the desired temperature, if any, andpressure to concurrently weaken and melt-stabilize the first layer 11 ata plurality of locations.

The patterned calendar roll 110 is configured to have a circularcylindrical surface 114, and a plurality of protuberances or patternelements 116 which extend outwardly from surface 114. The protuberances116 are disposed in a predetermined pattern with each protuberance 116being configured and disposed to precipitate a weakened, melt-stabilizedlocation 202 in the first layer 11 to effect a predetermined pattern ofweakened, melt-stabilized locations in the first layer 11. As shown inFIG. 2, repeating pattern of protuberances 116 may extend around aportion, or portions of the circumference of surface 114 of the calendarroll 110. Alternatively, the protuberances 116 may extend about theentire circumference of the surface 114. The protuberances 116 arepreferably rectangular shape cross sections which extend radiallyoutwardly from surface 114 and which have elliptical distal end surfaces117 although it is not intended to thereby limit the scope of thepresent invention to protuberances of only this configuration. Othersuitable shapes for distal ends 117 include, but are not limited tocircular, square, rectangular, etc. The roll 110 is finished so that allof the end surfaces 117 lie in an imaginary right circular cylinderwhich is coaxial with respect to the axis of rotation of roll 110.

Protuberances 116 are disposed in a regular predetermined pattern ofrows and columns in the embodiment shown in FIG. 2, although it is notintended to thereby limit the scope of the present invention to thepattern of protuberances of only this configuration. The protuberancesmay be disposed in any predetermined pattern about patterned calendarroll 110.

Anvil roll 112 is preferably a smooth surfaced, right circular cylinderof steel.

Another example of a weakening structure of the weakening unit 150 ofthe process 100 of FIG. 1 is shown in FIG. 3. Referring to FIG. 3,weakening arrangement 308 preferably comprises an ultrasonic transducer306 and a cylinder 310. As the first layer 11 is forwarded between theultrasonic transducer 306 and the anvil cylinder 310, the first layer 11is subjected to ultrasonic vibrational energy whereupon predeterminedpattern locations of the first layer 11 are weakened andmelt-stabilized.

Anvil cylinder 310 has a multiplicity of discrete pattern protuberanceswhich are generally designated 316 disposed on its outwardly facingsurface 314 in a predetermined pattern which extends about the entirecircumference of the anvil cylinder. The protuberances 316 can bedisposed in a predetermined pattern with each protuberance 316 beingconfigured and disposed to precipitate a weakened, melt-stabilizedlocation 302 in the first layer 11 to effect a predetermined pattern ofweakened, melt-stabilized locations in the first layer. Anvil 310 canhave a repeating pattern of protuberances 316 which extend around aportion, or portions of the circumference of surface 314. Alternatively,the protuberances 316 may extend about the entire circumference ofsurface 314.

Descriptions provided regarding protuberances 116 are applied toprotuberances 316. Anvil 310 is finished so that all of the end surfaceslie in an imaginary right circular cylinder which is coaxial withrespect to the axis of rotation of anvil cylinder 310.

After having passed through the weakening unit 150, prior to beingintroduced to forming unit 160, the first layer 11 includes a pluralityof weakened, melt-stabilized locations 202, 302 which generallycorrespond to the pattern of protuberances 116, 316, respectively.

Referring to FIG. 1, after having passed through the weakening unit 150,the second layer 12 is supplied onto at least part of the first layer 11to form a precursor web 10 before the precursor web 10 is fed into theforming unit 160. Though the process shown in FIG. 1 indicatesintroducing the second layer 12 onto the first layer 11 to form aprecursor web 10 and feeding the precursor web 10 into the forming unit160 are carried out sequentially, these two steps can be carried outsimultaneously.

The first layer 11 may have a longer width than a width of the secondlayer 12 in CD, and thus the precursor web 10 comprising the first layer11 and the second layer 12 may have at least one area, for example oneside of the precursor web 10 in MD, where the second layer 12 does notexist.

Referring to FIG. 1, the precursor web 10 is supplied to a forming unit160 where a plurality of first features, a plurality of second featuresand optional third features and/or fourth features are formed on theprecursor web 10 to provide a deformed web 20.

Various methods and apparatuses for deforming webs by forming discretefeatures on webs known in the art can be utilized to form the first andthe second features in the present application.

One type of features preferred for at least one of the first and thesecond features in the present invention are apertures. Various methodsand apparatuses for forming apertures are disclosed in patentliteratures. Patents disclosing such methods include: U.S. Pat. No.8,241,543, U.S. Pat. No. 3,355,974; U.S. Pat. No. 2,748,863 and U.S.Pat. No. 4,272,473 disclosing aperture forming methods using apparatushaving heated aperture forming elements; and U.S. Pat. No. 5,628,097disclosing a method for selectively aperturing a nonwoven web orlaminate of a nonwoven web and a polymeric film by weakening the web orthe laminate at a plurality of locations.

Another type of features preferred for the second discrete features inthe present invention are tufts. In many applications, it is desirablethat fibrous webs have a bulky texture and/or softness. As one example,a layered composite comprising a nonwoven layer in which nonwoven fibersprotrude, or are partially exposed through a polymer film can be usefulas a topsheet in absorbent articles as they provide an absorbentstructure in which the nonwoven acts as the conveyor of fluid from oneside of the composite to the other. The layered composite can bestructured such that the fluid collecting side of the layered compositeis a polymer film and nonwoven fibers protrude or are partially exposedthrough the polymer film to the fluid collecting side of the layeredcomposite. Various methods and apparatuses for forming tufts disclosedin patent literatures. Patents disclosing such methods include: WO1994/058117, WO 2004/59061, and WO 2010/117636 disclosing a method formaking tufts on a web using an apparatus comprising a roll comprising aplurality of ridges and grooves.

Referring to FIG. 1, formation of a plurality of first features and aplurality of second features occurs in formation unit 160, and can becarried out on any suitable apparatus that may comprise any suitabletype(s) of forming structure. Suitable types of forming structuresinclude, but are not limited to: a pair of rolls that define a niptherebetween, pairs of plates, belts, etc. Using an apparatus with rollscan be beneficial in the case of continuous processes, particularlythose in which the speed of the process is of interest. Although theapparatuses will be described herein for convenience primarily in termsof rolls, it should be understood that the description will beapplicable to forming structures that have any other suitableconfigurations.

The rolls used in the apparatuses and processes described herein aretypically generally cylindrical. The term “generally cylindrical”, asused herein, encompasses rolls that are not only perfectly cylindrical,but also cylindrical rolls that may have elements on their surface. Theterm “generally cylindrical” also includes rolls that may have astep-down in diameter, such as on the surface of the roll near the endsof the roll. The rolls are also typically rigid (that is, substantiallynon-deformable). The term “substantially non-deformable”, as usedherein, refers to rolls having surfaces (and any elements thereon) thattypically do not deform or compress under the conditions used incarrying out the processes described herein. The rolls can be made fromany suitable materials including, but not limited to steel, aluminum orrigid plastic. The steel may be made of corrosion resistant and wearresistant steel, such as stainless steel. The rolls may or may not beheated. If heated, consideration of thermal expansion effects must beaccommodated according to well known practices to one skilled in the artof thermo-mechanical processes.

The rolls may be meshing, non-meshing, or at least partiallyintermeshing. The terms “meshing” or “inter-meshing”, as used herein,refer to arrangements when the forming elements on one of members of theforming structure (e.g., roll) extend toward the surface of the otherforming structure and the forming elements have portions that extendbetween and below an imaginary plane drawn though the tips of theforming elements on the surface of the other forming structure. The term“non-meshing”, as used herein, refers to arrangements when the formingelements on one of the members of the forming structure (e.g., roll)extend toward the surface of the other forming structure, but do nothave portions that extend below an imaginary plane drawn through thetips of the forming elements on the surface of the other formingstructure. The term “partially intermeshing”, as used herein, refers toarrangements when the forming elements on one of the members of theforming structure (e.g., roll) extend toward the surface of the otherforming structure and some of the forming elements on the surface of thefirst roll have portions that extend between and below an imaginaryplane drawn through the tips of the forming elements on the surface ofthe other forming structure, and some of the elements on the surface ofthe first roll do not extend below an imaginary plane drawn through thetips of the forming elements on the surface of the other formingstructure.

The rolls typically rotate in opposite directions (that is, the rollsare counter-rotating). The rolls may rotate at substantially the samespeed, or at different speeds. The phrase “substantially the samespeed”, as used herein, means that there is less than 0.3% difference inthe speed. The speed of the rolls is measured in terms of surface orperipheral speed. Typically, when the web comprises polymeric materials,the rolls will rotate at substantially the same speed. If the webcomprises cellulosic materials, the rolls may rotate at differentspeeds. The rolls may rotate at different surface speeds by rotating therolls at different axial speeds, or by using rolls that have differentdiameters that rotate at the same axial speeds. The rolls may rotate atsubstantially the same speed as the speed at which the web is fedthrough the nip between the rolls; or, they may rotate at a greaterspeed than the speed at which the web is fed through the nip between therolls.

The rolls used in the apparatuses and methods described herein are usedto mechanically deform portions of the web material or materials. Themechanical deformation process may be used to permanently deformportions of the web and form the types of features in the web describedabove. The terms “mechanically deform” and “mechanical deformation”, asused herein, do not include hydroforming processes.

The rolls may have any suitable type of elements on their surface (orsurface configuration). The surface of the individual rolls may,depending on the desired type of mechanical deformation, be providedwith forming elements comprising: “male” elements such as discreteprojections, or continuous projections such as ridges; “female” elementsor recesses such as discrete or continuous voids in the surface of therolls; or any suitable combination thereof. The female elements may havea bottom surface (which may be referred to as depressions, cavities, orgrooves), or they may be in the form of apertures (through holes in thesurface of the rolls). In some embodiments, the forming elements on thecomponents (such as the rolls) of the forming structure may comprise thesame general type (that is, the opposing components may both have maleforming elements thereon, or combinations of male and female elements).

The forming elements may have any suitable shape or configuration. Agiven forming element can have the same plan view length and widthdimensions (such as a forming element with a circular or square shapedplan view). Alternatively, the forming element may have a length that isgreater than its width (such as a forming element with a rectangularplan view), in which case, the forming element may have any suitableaspect ratio of its length to its width. Suitable configurations for theforming elements include, but are not limited to: ridges and grooves,teeth having a triangular-shaped side view; columnar shapes; elementshaving plan view configurations including circular, oval, hour-glassshaped, star shaped, polygonal, and the like, and combinations thereof.Polygonal shapes include, but are not limited to rectangular,triangular, hexagonal, or trapezoidal. The forming elements can havetips that are flat, rounded or sharp. In certain embodiments, the shapesof the female elements may differ from the shapes of any mating maleforming elements. In certain embodiments, the female forming elementscan be configured to mate with one or more male forming elements.

The forming elements can be of any suitable size and have any suitablespacing. The center-to-center spacings among adjacent forming elementsmay be the same or different. The center-to-center spacing of theforming elements may range from the scale used for such micro-texturedwebs up to, or greater than, the examples of the size of thecenter-to-center spacing of the larger forming elements describedherein. Suitable configurations for the forming elements are describedbelow with exemplary forming structures such as ring rolls; SELFingrolls; IPS rolls, Micro-SELFing rolls, and RKA rolls; male/femaleembossing rolls.

FIG. 4 shows an embodiment of forming elements appropriate for ringrolling process. The rolls 164 and 166 are referred to herein as “ringrolls”. For ring rolling a web, each surface of rolls 164 and 166 has aplurality of alternating ridges 68 and grooves 70 extending around thecircumference of the rolls. In other embodiments, the ridges and groovesmay extend parallel to the axes A of the rolls. Referring to FIG. 4, theroll 164 includes a plurality of ridges 68 and corresponding grooves 70which extend about the entire circumference of roll 164. Roll 166includes a plurality of ridges 68 and a plurality of correspondinggrooves 70. Ridges 68 on roll 164 intermesh with or engage grooves 70 onroll 166, while ridges 68 on roll 166 intermesh with or engage grooves70 on roll 164.

As shown in FIG. 5, ring rolling can be used as incremental stretchingrolls to apply a tensioning force to a precursor web 10 comprising afirst layer 11 and second layer 12 wherein the first layer 11 hasweakened, melt-stabilized locations 202 to cause the first layer 11 ofthe precursor web 10 to rupture at the plurality of weakened,melt-stabilized locations 202 creating a plurality of apertures 22 inthe first layer coincident with the plurality of weakened,melt-stabilized locations 202. With respect to FIG. 5 or other figuresexcept FIG. 2, weakened, melt-stabilized locations 202 indicateweakened, melt-stabilized locations regardless forming process thereof,and are not limited to weakened, melt-stabilized locations formed by thestructure of a weakening unit shown in FIG. 2.

The positions of the precursor web 10 indicated in FIG. 5 is shown in areversed way to directly show melt-stabilized locations 202 in the firstlayer 11 and apertures 22 in the precursor web 10. That is, in theprocess 100 in FIG. 1, the second layer 12 is positioned on top of thefirst layer 11.

As the precursor web 10 passes through the ring rolls, the precursor web10 is subjected to tensioning in the cross-machine direction causing theprecursor web 10 to be extended in the CD direction. Alternatively, oradditionally the precursor web 10 may be tensioned in the machinedirection. The tensioning force placed on the precursor web 10 isadjusted such that it causes the weakened, melt-stabilized locations 202to rupture creating a plurality of apertures 22 coincident with theweakened melt-stabilized locations 202 in the precursor web 10. However,the bonds of the precursor web 10 are preferably strong enough such thatthey do not rupture during tensioning, thereby maintaining the precursorweb 10 in a coherent condition even as the weakened, melt-stabilizedlocations rupture. However, it may be desirable to have some of thebonds rupture during tensioning. Other exemplary structures ofincremental stretching mechanisms suitable for incrementally stretchingor tensioning the precursor web 10 are described in International PatentPublication No. WO 95/03765.

FIG. 6 shows a forming elements embodiment appropriate to form tufts orrib-like structures suitable for use in the processes and apparatusesdescribed herein. In FIG. 6, the top roll 164 is a ring roll havingcircumferential ridges 68 and grooves 70 as described with respect toFIG. 5, and the bottom roll 174 has forming elements which The Procter &Gamble Company's “SELF” or “SELFing” rolls have. The forming elements onthe SELF rolls, that is SELF teeth, can be oriented in either themachine direction (MD) or the cross-machine direction (CD). In theembodiment shown in FIG. 6, the SELF roll 174 comprises a plurality ofalternating circumferential ridges 76 and grooves 78. The ridges 76 havespaced apart channels 80 formed therein that are oriented parallel tothe axis A of the roll. The channels 80 form breaks in the ridges 76that create discrete forming elements or teeth 82 on the SELF roll 174.Forming elements, the teeth 82, have their longer dimension oriented inthe MD. The SELF configuration shown in FIG. 6 will be referred toherein as a standard “CD SELF” since the teeth are aligned in rows inthe MD and CD, and in the usual SELF process, the material being fedinto the nip N having such a SELF configuration would be stretched inthe CD.

In other embodiments, which are described in the SELF patents that areincorporated by reference herein, the SELF roll can comprise a machinedirection, or “MD SELF” roll. Such a roll will have alternating ridgesand grooves that are oriented parallel to the axis A of the roll. Theridges in such a roll have spaced apart channels formed therein that areoriented around the circumference of the roll. The channels form breaksin the ridges to form discrete forming elements or teeth on the MD SELFroll. In the case of MD SELF rolls, the teeth have their longerdimension oriented in the CD.

FIG. 7A shows another embodiment of forming elements to form tufts ortuft like features suitable for use in the processes and apparatusesdescribed herein. In this embodiment, the roll 190 comprises a variationof one of The Procter & Gamble Company's CD SELF rolls. As shown in FIG.7A, the surface of the roll has a plurality of spaced apart teeth 32.The teeth 32 are arranged in a staggered pattern. More specifically, theteeth 32 are arranged in a plurality of circumferentially-extending,axially-spaced rows, such as 102A and 102B, around the roll. But for thespacing TD between the teeth in each row, the teeth in each roll wouldform a plurality of circumferentially-extending, axially-spacedalternating ridges and grooved regions. The tooth length TL and machinedirection spacing TD can be defined such that the teeth in adjacent rows102A and 102B either overlap or do not appear to overlap when the rollsare viewed from one of their ends. In the embodiment shown in FIG. 7A,the teeth 32 in adjacent rows are circumferentially offset by a distanceof about 0.5x (where “x” is equal to the tooth length TL plus the MDspacing TD between teeth in a given row). In other words, the leadingedges LE of adjacent teeth in adjacent rows will be offset in the MD byabout 0.5x.

The roll 190 can be aligned with an opposing roll which has ridges andgrooves therein so that the rows of teeth in one roll align with thegrooved regions between the teeth in the opposing roll. The staggeredtooth pattern allows the precursor web 10 to be mechanically impacted toform features in a staggered pattern.

FIG. 7B shows in cross section a portion of the intermeshing rolls 166and 174 shown in FIG. 6 including teeth 82 which appear as ridges 76 andgrooves 78 between the teeth 82. The teeth can have a triangular orinverted V-shape when viewed in cross-section. The vertices of teeth areoutermost with respect to the surface of the rolls. As shown in FIGS. 7Aand 7B, teeth 82 that have a tooth height TH, a tooth length TL, and atooth-to-tooth spacing (or ridge-to-ridge spacing) referred to as thepitch P. For staggered rolls, the pitch is equal to the spacing betweenadjacent rows of forming elements. The tooth length TL in suchembodiments is a circumferential measurement. The outermost tips of theteeth have sides that are preferably rounded to avoid cuts or tears inthe precursor material. The size and shape of the tooth tip may bespecified via the tip radius TR. The leading and trailing edges of theteeth may have a radius as well, or the teeth may form a right angle(and have no radius). As shown, the ridges 68 of one roll extendpartially into the grooves 78 of the opposed roll to define a “depth ofengagement” DOE, which is a measure of the level of intermeshing ofrolls 164 and 174. The depth of engagement can be zero, positive formeshing rolls, or negative for non-meshing rolls. The depth ofengagement DOE, tooth height TH, tooth length TL, tooth spacing TD, tipradius TR, and pitch P can be varied as desired depending on theproperties of precursor web 10 and the desired characteristics of adeformed web from the precursor web 10.

The teeth can have any suitable dimensions. In certain embodiments ofthe SELF rolls, the teeth can have a length TL ranging from about 0.5 mm(0.020 inches) to about 13 mm (0.512 inches) and a spacing TD from about0.5 mm to about 13 mm, a tooth height TH ranging from about 0.5 mm toabout 17 mm (0.669 inches), a tooth tip radius TR ranging from about0.05 mm (0.002 inches) to about 0.5 mm (0.020 inches), and a pitch Pbetween about 1 mm (0.040 inches) and 10 mm (0.400 inches). The depth ofengagement E can be from about −1 mm to about 16 mm (up to a maximumapproaching the tooth height TH). Of course, E, P, TH, TD, TL, and TRcan each be varied independently of each other to achieve the desiredproperties in the web.

FIG. 7C shows an alternative forming elements embodiment appropriate toform tufts or rib-like structures suitable for use in the processes andapparatuses described herein. The roll 192 is referred to herein as an“MD staggered SELF” roll in which the teeth 42 are oriented with theirlonger dimension oriented in the CD and are staggered. The roll 192 hascircumferentially extending channels 94 formed between the teeth.

FIG. 8 shows an alternative forming elements embodiment to formapertures suitable for use in the processes and apparatuses describedherein. In FIG. 8 the top roll 164 is a ring roll, and the bottom roll104 is referred to herein as a Rotary Knife Aperturing (or “RKA”) roll.As shown in FIG. 8, the rolls comprise a pair of counter-rotating,intermeshing rolls, wherein the top roll 164 comprisescircumferentially-extending ridges 68 and grooves 70, and the bottomroll 104 comprises pyramid shaped teeth 52 with at least six sides, thesides being substantially triangular and being tapered from a base to atip. The teeth 52 are arranged in spaced apart circumferential rows withgrooves 54 therebetween. The teeth 52 are joined to the bottom roll 104at the base, and the base of the tooth has a cross-sectional lengthdimension greater than a cross-sectional width dimension. Typically,apertures are formed in the precursor web 11 as the teeth 52 on the RKAroll 104 intermesh with grooves 70 on the other roll 164. With respectto tooth height, tooth spacing, pitch, depth of engagement, and otherprocessing parameters, RKA and the RKA apparatus can be the same asdescribed herein with respect to SELF or Micro-SELF.

FIG. 9 shows a portion of the nip between a pair of rolls having analternative forming elements to form embossing for use in the processesand apparatuses described herein. As shown in FIG. 9, male/femaleembossing apparatus comprises at least a first and a second patternedroll 214 and 216. The first patterned roll 214 has a male embossingpattern, comprising one or more projections 218 which may be discreteelements (e.g., dot and/or line) embossing elements. The secondpatterned roll 216 has a female embossing pattern comprising one or morerecesses 220, which may be discrete (e.g., dot and/or line configuredrecesses), into which one or more of the projections of the firstpatterned roll mesh. The rolls may have matched or unmatched patterns.The elements on the rolls can be of any suitable size and shape. Whenthe embossing rolls have unmatched embossing patterns, they wereengraved independently from each other. The rolls 214 and 216 in such anembodiment have enlarged sidewall clearances between adjacent,inter-engaged projections 218 and recesses 220 of the embossingpatterns.

FIG. 10 shows a forming structure 132 as an exemplary forming unit 160for making a deformed web 20 according to the present invention. Formingstructure 132 can provide a deformed web 20 having a plurality of firstfeatures (apertures in this case) in the first layer only and aplurality of second features (tufts in this case) throughout both thefirst and second layers. Precursor web 10 comprising a first layer 11and a second layer 12 has a plurality of weakened, melt-stabilizedlocations 202 in at least one predetermined area, a first area, of firstlayer 11. The first area of the first layer 11 confines a first area ofthe precursor web 10 or the deformed web 20.

The forming structure 132 comprises a pair of rolls 134 and 136 having anip 130, each rotating about parallel axes A.

A first roll 134 comprises a first region 111 comprising a plurality ofcircumferentially-extending ridges 68 separated by grooves 70 which workas first forming elements, and two second regions 113 comprising aplurality of circumferentially-extending ridges 68″ separated by grooves70″. The first forming elements apply a tensioning force to theprecursor web 10 to cause the first layer 11 to rupture at the pluralityof wakened, melt-stabilized locations creating a plurality of aperturesin the first layer coincident with the plurality of weakened,melt-stabilized locations.

The circumferentially-extending ridges 68 and grooves 70 in the firstregion 111 may have the same dimensions as thecircumferentially-extending ridges 68″ and grooves 70″ in the secondregion 113 as well known in the art of “ring-rolling”. Thecircumferentially-extending ridges 68 and grooves 70 in the first region111 may differ in their dimensions from the circumferentially-extendingridges 68″ and grooves 70″ in the second region 113.

A second roll 136 comprises a first region 121 havingcircumferentially-extending ridges 68′ separated by grooves 70′, ringroll elements. In addition to region 121, roll 136 has two secondregions 123 comprising ridges having formed therein second formingelements 62, the toothed ridges separated by grooves 64. The secondforming elements can, for example, comprise standard or staggered CDSELF teeth or MD SELF teeth, RKA teeth such as shown in FIG. 8, anotherraised ridge RKA teeth, raised ridge SELF teeth disclosed in WO2012/149074A, or standard or staggered IPS teeth disclosed in U.S. Pat.No. 7,648,752. In the particular embodiment shown in FIG. 10, the secondforming elements comprise staggered CD SELF teeth or CD IPS teeth. Thetips of at least some of the second forming elements 62 of roll 136extend inward toward the axis of the roll 134 to a depth beyond the topof at least some of the ridges 68″ on the second roll 134.

At least some of ridges 68′ and grooves 70′ in the first region 121 ofroll 136 and at least some of ridges 68 and grooves 70 in the firstregion 111 of roll 134 are intermeshed, and incrementally stretchprecursor web 10 to form apertures 22 in the first layer 11 coincidentwith a plurality of weakened, melt-stabilized locations 202. The ridges68 and grooves 70 in the first region 111 of the roll 134 may have thesame dimensions as the ridges 68′ and grooves 70′ in the first region121 of the roll 136 as well known in the art of “ring-rolling”. Ofcourse, precursor web 10 has melt-weakened locations 202 formed thereinprior to precursor 10 entering the nip 130 of forming structure 132. Inaddition, at least some of ridges 68″ of roll 134 are intermeshed withat least some of the grooves 64 of roll 136 to form tufts in theprecursor web 10.

In one embodiment, the second forming elements 62 of roll 136 arestandard or staggered CD SELF teeth or CD IPS teeth and applied in anarea of a precursor web 10 comprising the first layer 11 and the secondlayer 12. Obtained deformed web 20 comprising the first layer 11 and thesecond layer 12 has a first surface 30 comprising the first layer 11 anda plurality of discrete tufts or rib-like structures 24 including fibersintegral with and extending from the second layer 12 toward the firstlayer 11. In case of tufts, each of the tufts 24 has a tuft baseproximal to the second layer 12 and a distal portion opposing the tuftbase. Tufts may be formed in both layers; or, the tuft of one layer mayburst through the other layer as described in greater detail in U.S.Pat. No. 7,648,752. At least part of the distal portion of each of thetufts 24 may be covered by a cap, each cap being an integral extensionof the first layer 11 extending over the distal portion of a discretetuft. Forming capped tufts is described in greater detail in WO2010/117636. In a non-limiting example, the first layer 11 is a polymerfilm layer and the second layer 12 is a nonwoven layer. In anothernon-limiting example, both the first layer 11 and the second layer 12are nonwoven layers.

The process according to the present invention, the first features areformed in the first layer but not in the second layer, and the secondfeatures by the second forming elements such as teeth 62 in FIG. 10 areformed through the entire web in z-dimension.

One advantage of the process and/or apparatus described above is thatthe deformed web can be produced in-line with other production equipmenton a manufacturing line for producing disposable absorbent articles. Forexample, a process or an apparatus such as the weakening unit 150 or theforming unit 160 shown in FIG. 1 can be inserted as a unit operationinto an existing manufacturing line. As unit operations themselves, suchapparatuses can be modular such that they can be changed out relativelyquickly and easily with other modular unit operations. When used as partof a manufacturing line for sanitary napkins, for example, theconstituent rolls need not be much wider than the product itself,thereby providing for relatively quick and easy installation andremoval.

In FIG. 10, at least one of roll 134 or 136 may further comprise aplurality of fourth forming elements (not indicated in FIG. 10) to forma plurality of fourth features on precursor web 10. The fourth formingelements may be located in a fourth region separate from either thefirst region or the second region of roll 134 or 136. The fourth formingelements may be located in a second region in roll 134 or 136 resultinga plurality of fourth features intermixed with the second features.

FIG. 11 shows another forming structure 232 as an exemplary forming unit160 for making a deformed web 20 according to the present invention. Therolls are configured to deform a precursor web 10 with at least threesets of deformations. At least two of the three deformations orient indifferent directions each other relative to the surface of deformed web20 that is in z-dimension in the web. The forming structure 232 canprovide a deformed web 20 having a plurality of first features(apertures 22 in FIG. 11), a plurality of second features (tufts 24 inFIG. 11) and a plurality of third features (tufts or rib-like structures26 in FIG. 11). Precursor web 10 comprising a first layer 11 and asecond layer 12 has a plurality of melt-weakened locations 202 in atleast one predetermined area, a first area, in the first layer 11. Thefirst area of the first layer confines a first area of the precursor web10 or deformed web 20.

Referring to FIG. 11, the forming structure 232 comprises a pair ofrolls 234 and 236 having a nip 230, each rotating about parallel axes A.The pair of intermeshing rolls 234 and 236 operates to form the first,second and third features on precursor web 10.

A first roll 234 comprises a first region 111 comprising a plurality ofcircumferentially-extending ridges 68 separated by grooves 70 as firstforming elements, two second regions 113 comprising a plurality ofcircumferentially-extending ridges 68″ separated by grooves 70″, and twothird regions 115 comprising a plurality of third forming elements,teeth 72 in this case, separated by grooves 74 on its surface. In oneembodiment, the third forming elements can, for example, comprisestandard or staggered CD SELF teeth or MD SELF teeth, RKA teeth such asshown in FIG. 8, another raised ridge RKA teeth, raised ridge SELF teethdisclosed in WO 2012/149074A, or standard or staggered IPS teethdisclosed in U.S. Pat. No. 7,648,752.

A second roll 236 comprises a first region 121 comprising a plurality ofcircumferentially-extending ridges 68′ separated by grooves 70′; twosecond regions 123 comprising ridges having formed therein secondforming elements 62, the toothed ridges separated by grooves 64; and twothird regions 125 comprising a plurality of circumferentially-extendingridges 68′″ separated by grooves 70′″ on its surface. Descriptions forthe process and apparatus stated with respect to FIG. 10 are applicablefor the process and apparatus of FIG. 11. In addition, at least some ofthe third forming elements in the first roll 234, teeth 72 in FIG. 11comprising staggered CD SELF teeth or CD IPS teeth extend inward towardthe axis of the second roll 236 beyond at least some of the ridges 68″‘in the third region of the second roll 236 to form the plurality ofthird features. That is, at least some of grooves 70″’ of roll 236 areintermeshed with at least some of teeth 72 of roll 234 to form the tuftsor rib-like structures 26 in the precursor web 10. The third formingelements, teeth 72 in FIG. 1 are explained further in FIG. 14B and FIG.15 later.

In a particular embodiment as shown in FIG. 11, the precursor web 10 andthe deformed web 20 comprise an area 36 in outer sides thereof along amachine direction where the second layer 12 does not exist, and thethird features (tufts or rib-like structures 26 in FIG. 11) are formed.In such an embodiment, at least majority of tufts or rib-like structures26 may be formed to side areas 36 of the precursor web 10 predeterminedto be flaps of a sanitary napkin. In an alternative embodiment, theprecursor web 10 and the deformed web 20 comprise the first layer 11 andthe second layer 12 in a substantially entire area and the thirdfeatures are formed through the entire thickness of the precursor web10.

In some embodiments, the second roll 236 has a longer roll diameter inthe second regions than in the first region and/or the third region.This design of the second roll 236 is preferred especially when thefirst layer 11 is a polymeric film layer.

Referring to FIGS. 10 and 11, in one embodiment, at least majority ofthe melt-weakened locations are limited to the central region ofprecursor web 10, for example, predetermined to be a central region inan absorbent article like a sanitary napkin.

FIG. 12 shows an embodiment of a deformed web 20 made by a process ofthe present invention using the apparatus shown in FIG. 11, in which thefirst forming elements are ring roll elements, the second and thirdforming elements are staggered CD SELF teeth. In FIG. 12, the deformedweb 20 comprises a first surface 30 not contacting the second layer 12,first features comprising a plurality of spaced apart apertures 22formed on the first layer 11, second features comprising a plurality ofspaced apart tufts 24 formed throughout the first and second layerstowards the first surface 30 of the web 20, and third featurescomprising a plurality of spaced apart tufts or rib-like structure 26formed on a first layer towards opposite to the first surface 30. InFIG. 12, the apertures 22, tufts 24, and tufts or rib-like structure 26may be aligned in rows in the MD.

FIG. 13 is a view of intermeshing engagement of portions of the formingstructure of FIG. 11.

FIG. 14A shows a portion of one embodiment of a first roll 234 whereridges 68 and grooves 70, and teeth 72 separately by grooves 74 asexemplary third forming elements are shown. FIG. 14B shows a portion ofone embodiment of a second roll 236 having circumferentially-extendingridges 68′, 68′″ and grooves 70′, 70′″, and teeth 62 as an exemplarysecond forming elements.

An enlarged view of the teeth 72 shown in FIG. 14A is shown in FIG. 15.As shown in FIG. 15, each tooth 72 has a tip 711, a leading edge LE anda trailing edge TE. The tooth tip 711 can be rounded to minimize fiberbreakage and is preferably elongated. Referring to the apparatus in FIG.11 and FIG. 15, in one embodiment when the first layer 11 of theprecursor web 10 is a polymer film, a deformed web 20 tends to stick toteeth 72 upon being pulled off of roll 234. This sticking issue is moreconcerned when third features are formed in the area 36 of a precursorweb where the first layer is a polymer film. In order to smoothly pulloff the deformed web 20 from roll 234, teeth 72 may have a side wallangle (“D”) of in the range of from about 8 to about 14 degrees in atleast LE. The side wall angle is an angle the longer sides of the teethmake relative to an imaginary vertical line extending outward from thecentral axis of the roll through the center of the teeth. Any radius atthe tips of the teeth is ignored. LE and TE in the teeth 72 may have thesame degree of side wall angle. LE and TE in the teeth 72 may havedifferent degrees of side wall angle.

FIG. 16 is a schematic side view of another embodiment of a formingstructure 160 preferable for the present invention. Referring to FIG.11, when deformed web 20 tends to stick to second forming elements 62and/or third forming elements 72 upon being pulled off from roll 234,236, various processing aids can be added as necessary. Formation of thethird features in the outer sides a precursor web 10 where only thefirst layer 11 exists, especially when the first layer 11 is a polymerfilm, the stickiness issue tends to deteriorate. In one embodiment, asshown in FIG. 16, deformed web 20 exits nip 230 and is directed off ofroll 234 over various guide rolls 105 as necessary before being woundfor further processing, shipping, or placement for incorporation in amanufactured product. The process of the present invention employsguiding the deformed web 20 to a guide roll 105 which is located in away that a center of the guide roll and a center of the first roll 234are in a line substantially parallel to the machine direction.“Substantially parallel to the machine direction” herein means that animaginary line connecting a center of the guide roll and a center of thefirst roll, and a machine direction form an angle in the range of fromabout 0 to about 5 degrees.

The guide roll is placed preferably from about 2 to about 5 mm away fromthe surface of first roll 234 having third features in each side inmachine direction of the roll. If it is placed too far away from firstroll 234, it cannot peel the web off as effective. If it is too closefrom roll 236, there is risk of damaging the guide roll or roll 234. Inaddition, known various processing aids can be added as necessary. Forexample, non-stick treatments such as silicone or fluorocarbontreatments can be added. Various lubricants, surfactants or otherprocessing aids can be added to the precursor web 20 or to the rolls234, 236. Other methods of aiding the removal of the web from the rollinclude air knives or brushing.

The present invention is also directed to a process for producing anabsorbent article comprising a liquid permeable topsheet comprising aplurality of first features, apertures, formed in a first area and aplurality of second features formed in a second area of the tophseet,and a liquid impermeable backsheet in a continuous matter. The processcomprises the steps of: supplying a first layer of a precursor topsheet;weakening the first layer at a plurality of locations to create aplurality of weakened, melt-stabilized locations in a first area of thefirst layer; supplying a second layer of the precursor topsheet onto atleast the first area of the first layer; forming a plurality of firstfeatures and a plurality of second features in the precursor topsheet;supplying a precursor backsheet onto the second layer of the precursortopsheet and integrating the precursor topsheet and the precursorbacksheet to form an absorbent article assembly; and severing theabsorbent article assembly into individual absorbent articles. The firstarea of the first layer confines the first area of the precursortopsheet. The plurality of first features are formed in the first areaof the precursor topsheet coincident with the plurality of weakened,melt-stabilized locations throughout the first layer but not the secondlayer. The plurality of second features are formed throughout the firstand second layers in a second area of the precursor topsheet in thez-direction.

The process for producing an absorbent article according to the presentinvention may further comprise of a step of supplying an absorbent corejoined with the backsheet and the topsheet or an optional liquidacquisition layer deposited below the topsheet; and/or a step ofsupplying a liquid acquisition layer joined with the topsheet and thebacksheet or an optional absorbent core deposited above the backsheet,both in any manner as is known by supply and attachment means such asthose well known in the art.

Various methods and apparatuses for producing absorbent articles such assanitary napkins and diapers known in the art can be utilized to conductthe process of the present invention.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “90°” is intended to mean“about 90°”.

It should be understood that every maximum numerical limitation giventhroughout this specification includes every lower numerical limitation,as if such lower numerical limitations were expressly written herein.Every minimum numerical limitation given throughout this specificationwill include every higher numerical limitation, as if such highernumerical limitations were expressly written herein. Every numericalrange given throughout this specification will include every narrowernumerical range that falls within such broader numerical range, as ifsuch narrower numerical ranges were all expressly written herein.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention. To the extent that any meaning ordefinition of a term in this written document conflicts with any meaningor definition of the term in a document incorporated by reference, themeaning or definition assigned to the term in this written documentshall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A process for deforming a multilayer web, theprocess comprising the steps of a) supplying a first layer of aprecursor web; b) weakening the first layer at a plurality of locationsto create a plurality of weakened, melt-stabilized locations in a firstarea of the first layer; c) supplying a second layer of the precursorweb onto at least the first area of the first layer; d) forming aplurality of first features and a plurality of second features in theprecursor web, wherein the first area of the first layer confines afirst area of the precursor web, wherein the plurality of first featuresare apertures formed in the first area of the precursor web coincidentwith the plurality of weakened, melt-stabilized locations throughout thefirst layer but not the second layer, wherein the plurality of secondfeatures are formed throughout the first and second layers in a secondarea of the precursor web in the z-direction, and wherein the pluralityof first features and the plurality of second features are formedsimultaneously.
 2. The process according to claim 1, wherein the firstlayer in step b) is weakened by a means selected from a group consistingof heat, pressure and a combination thereof.
 3. The process according toclaim 1, wherein the first features are formed by applying a tensioningforce to the precursor web to cause the first layer to rupture at theplurality of weakened, melt-stabilized locations creating a plurality ofapertures in the first layer.
 4. The process according to claim 1,wherein at least majority of the plurality of first features are formedin a region of the precursor web predetermined to be a central region ofa sanitary napkin.
 5. The process according to claim 1, wherein the stepd) further forms a plurality of third features in the precursor websimultaneously with forming the plurality of first features and theplurality of second features.
 6. The process according to claim 1,wherein the precursor web comprises a third area along a machinedirection in each outer side of the precursor web where the second layerdoes not exist.
 7. The process according to claim 6, wherein the step d)further forms a plurality of third features in the third area in eachouter side of precursor web simultaneously with forming the plurality offirst features and the plurality of second features.
 8. The processaccording to claim 7, wherein the third area is predetermined to beflaps of a sanitary napkin.
 9. The process according to claim 7, whereinthe plurality of second features and the plurality of third features areformed in an opposite direction in Z-dimension.
 10. The processaccording to claim 1, wherein the first layer comprises a materialselected from a group consisting of a polymeric film, a nonwoven and acombination thereof.
 11. The process according to claim 10, wherein thefirst layer comprises a polymer film.
 12. The process according to claim10, wherein the second layer comprises a nonwoven.
 13. The processaccording to claim 1, wherein the plurality of second features arefeatures selected from the group consisting of apertures, protrusions,depressions, tufts and combinations thereof.
 14. The process accordingto claim 1, wherein the plurality of first features and the plurality ofand second features in step d) are formed by feeding the precursor webin a machine direction into a nip that is formed between twointermeshing rolls comprising; a first roll having a surface, acircumference and an axis, and comprising a first region comprising aplurality of first forming elements wherein the plurality of firstforming elements comprise a plurality of circumferentially-extendingridges separated by grooves, and a second region comprising a pluralityof circumferentially-extending ridges separated by grooves on itssurface; and a second roll having a surface, a circumference and anaxis, and comprising a first region comprising a plurality ofcircumferentially-extending ridges separated by grooves, and a secondregion comprising a plurality of second forming elements on its surface,and when the precursor web is fed into the nip, at least some of theplurality of first forming elements in the first region of the firstroll and at least some of the plurality of circumferentially-extendingridges in first region of the second roll are intermeshed to from theplurality of first features, and at least some of the second formingelements in the second roll extend inward toward the axis of the firstroll beyond at least some of the plurality ofcircumferentially-extending ridges in the second region of the firstroll to form the plurality of second features.
 15. The process accordingto claim 14, wherein the process further comprises guiding the precursorweb after step d) to a guide roll which is located in a way that acenter of the guide roll and a center of the first roll is in a linesubstantially parallel to the machine direction.
 16. The processaccording to claim 9, wherein the plurality of first features, theplurality of second features and the plurality of third features in stepd) are formed by feeding the precursor web in a machine direction into anip that is formed between two intermeshing rolls comprising a firstroll having a surface, a circumference and an axis, and comprising afirst region comprising a plurality of first forming elements whereinthe plurality of first forming elements comprise a plurality ofcircumferentially-extending ridges separated by grooves, a second regioncomprising a plurality of circumferentially-extending ridges separatedby grooves, and a third region comprising a plurality of third formingelements on its surface; and a second roll having a surface, acircumference and an axis, and comprising a first region comprising aplurality of circumferentially-extending ridges separated by grooves, asecond region comprising a plurality of second forming elements on itssurface, and a third region comprising a plurality ofcircumferentially-extending ridges separated by grooves on its surface,and when the precursor web is fed into the nip, at least some of theplurality of first forming elements in the first region of the firstroll and at least some of the plurality of circumferentially-extendingridges in the first region of the second roll are intermeshed to fromthe plurality of first features; at least some of the second formingelements in the second roll extend inward toward the axis of the firstroll beyond at least some of the plurality ofcircumferentially-extending ridges in the second region of the firstroll to form the plurality of second features; and at least some of thethird forming elements in the first roll extend inward toward the axisof the second roll beyond at least some of the plurality ofcircumferentially-extending ridges in the third region of the secondroll to form the plurality of third features.
 17. The process accordingto claim 16, wherein the plurality of third forming elements comprisesteeth, each of the teeth having a leading edge and a trailing end,wherein each of the teeth has a draft angle in the range of from about 8to about 14 degrees at the leading end.
 18. The process according toclaim 16, wherein the process further comprises guiding the precursorweb after step d) to a guide roll which is located in a way that acenter of the guide roll and a center of the first roll is in a linesubstantially parallel to the machine direction.
 19. A process forfabricating an absorbent article, the absorbent article comprising aliquid permeable topsheet and a liquid impermeable backsheet, the methodcomprising the steps of: a) supplying a first layer of a precursortopsheet; b) weakening the first layer at a plurality of locations tocreate a plurality of weakened, melt-stabilized locations in a firstarea of the first layer; c) supplying a second layer of the precursortopsheet onto at least the first area of the first layer; d) forming aplurality of first features and a plurality of second features in theprecursor topsheet; e) supplying a precursor backsheet onto the secondlayer of the precursor topsheet and integrating the precursor topsheetand the precursor backsheet to form an absorbent article assembly; andf) severing the absorbent article assembly into individual absorbentarticles, wherein the first area of the first layer confines a firstarea of the precursor topsheet, wherein the plurality of first featuresare apertures formed in the first area of the precursor topsheetcoincident with the plurality of weakened, melt-stabilized locationsthroughout the first layer but not the second layer, wherein theplurality of second features are formed throughout the first and secondlayers in a second area of the precursor topsheet in the z-direction,and wherein the plurality of first features and the plurality of secondfeatures are formed simultaneously.
 20. The process according to claim19, wherein the steps of a) to f) are carried out in a continuousmanner.